World-Class Motion Control with Worldwide Support

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1 Rockwell Automation is an automation leader who not only develops innovative technology, but has the expertise and global supply network to be your complete automation solution provider. Rockwell Automation offers worldwide customer support capabilities. And, through a network of partnerships, Rockwell Automation brings together reliable, knowledgeable people from all corners of the automation world to meet your needs. As a part of Complete Automation TM, the Ultra3000 family of world-class motion control products was designed with built-in reliability for long life and superior performance. In addition to stand-alone control, the Ultra3000 offers the flexibility of platform integration with ControlLogix and SoftLogix. This flexibility provides you with the most efficient flow of information to meet your needs from the simplest device to the highest-level information system. You can depend on Complete Automation to help you achieve increased productivity and lower total cost of ownership. World-Class Motion Control with Worldwide Support To put the U l t r a3000 to work for you, Rockwell Automation has a worldwide network of s a l e s and service engineers and authorized system integrators. To g e t h e r, they offer the industry s broadest range of support services to help you implement your motion control solution. Our Motion Solution Managers are specialists in motion control and servo drive technology. They have the expertise to evaluate your application requirements and help you achieve the optimum solution. Rockwell Automation Global Manufacturing Solutions offers application engineering services, system startup, training, field service, and ongoing product support. They a l s o offer an emergency HELP line a h o u r, toll-free evaluation and service connection. Our network of authorized motion control system integrators can provide complete integration services for new, retrofit, or rebuild requirements worldwide. For more information on the U l t r a3000 or any of our support services, contact your nearest Rockwell Automation sales office or motion control distributor, or refer to our Web site: w w w. a b. c o m / m o t i o n Allen-Bradley, A-B, Kinetix and ControlLogix are registered trademarks of Rockwell Automation. PLC, Ultraware, Ultra3000, Ultra3000i, Ultra3000-SE, RSLogix 5000 and DeviceNet are trademarks of Rockwell Automation. SERCOS interface is a trademark of the Interests Group SERCOS interface e.v. (IGS). DeviceNet is a trademark of Open DeviceNet Vendor Association. Corporate Headquarters Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, USA, Tel: (1) , Fax: (1) Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI USA, Tel: (1) , Fax: (1) Europe: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36-BP 3A/B, 1170 Brussels, Belgium, Tel: (32) , Fax: (32) Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) , Fax: (852) Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC USA, Tel: (1) , Fax: (1) Europe: Rockwell Automation, Brühlstraße 22, D Elztal-Dallau, Germany, Tel: (49) , Fax: (49) Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore , Tel: (65) , Fax: (65) Publication 2098-BROO2D-EN-P September 2004 Supersedes Publication 2098-BR002C-EN-P May 2003 Copyright 2004 Rockwell Automation, Inc. All Rights Reserved. Printed in U.S.A.

2 Ultimate Performance. Ultimate Flexibility. Ultra3000 Digital Servo Drives

3 Providing A Global Solution The Ultra3000 family creates a complete set of servo drive products ranging from simple standalone indexing applications to multi-axis integrated motion. These high-performance, digital servo drives meet global voltage requirements and provide flexibility to perform in a variety of machine control architectures. In addition, the Ultra3000 drive is integrated with both the C o n t r o l L o g i x and SoftLogix platforms via SERCOS i n t e r f a c e for Kinetix Integrated Motion. The Ultra3000i digital servo drive with indexing adds basic control capability to the Ultra3000 feature set. The Ultra3000 and Ultra3000i use the Ultraware software configuration and diagnostic tool set, which includes sophisticated digital scope capability, a comprehensive array of diagnostics, and a file management system that helps organize multiple configuration files and motion programs. The Ultra3000 with SERCOS drive, part of the Kinetix Integrated Motion solution, is configured through RSLogix 5000 software providing one platform for both motion and machine control. To complete your system, the entire Ultra3000 family operates a wide variety of Allen-Bradley h i g h -performance rotary servo motors. The Ultra3000 also offers seamless support of highp e rformance linear motors for your most demanding linear motion applications. A Broad Range of Power and Flexibility The Ultra3000 provides simple integration into Allen-Bradley machine control architectures. The Ultra3000 can operate a wide variety of brushless servo motors, including Allen-Bradley MP-, F- and Y- Series and 1326AB motors along with linear and third-party motors. Ultra3000 drives use Smart Motor Technology to provide automatic identification of the specific motor connected to the drive. This reduces commissioning time and safeguards against incorrect motor replacement. The Ultra3000 family accepts high resolution encoder feedback for d emanding, high precision applications. The Ultra3000 incorporates applicationproven designs, tested individually and within overall architectures, to provide world-class reliability and increase your machine productivity. The Ultra3000i s built-in indexing c a p ab i l i t y can eliminate the need for a motion controller or PLC card for point to p o i n t positioning moves. To eliminate costly and time consuming machine homing cycles, the Ultra3000 has built-in support for multi-turn absolute encoders or an option to supply external logic power to maintain position during power loss. With Ultraware software the Ultra3000 has a powerful commissioning and diagn o s t i c tool designed to increase your productivity and optimize system performance quickly and easily. When using the Ultra3000 with RSLogix 5000 software as an integrated motion solution, programmers can easily configure and add drives and motion axes using wizard-based configuration dialogs. Ultra Amp Servo Drive Ultra3000 Features: V AC options, single and three phase input SERCOS or DeviceNet connectivity options 7.5A to 150A peak current capability Standard high-density D-Shell connectors Field programmable flash memory firmware storage Seven segment LED for status and error codes Eight selectable general purpose inputs Four selectable general purpose outputs and relay output Serial port for RS-232/RS-485 c o m m u n i c a t i o n s CE compliance and UL listed to U.S. and Canadian safety standards 1 SoftLogix with SERCOS interface is available with RSLogix 5000 version 12 or higher. Ultra Family 2

4 Kinetix : The New Science of Integrated Motion The Ultra3000 as Part of the Kinetix Integrated Motion Solution Kinetix Integrated Motion is a combination of architecture, A-B world class motion products, and motion application expertise. This true integrated motion solution helps save you time and money while increasing productivity. Your application moves along s m o o t h l y, with improved performance and effortless precision. As part of the Kinetix solution, the Ultra3000 is designed to provide OEM machine b u i l d e r s integration into Allen-B r a d l e y s Logix platform via direct SERCOS digital interface. The Logix technology combines motion and sequential control functionality into a single multi-tasking control platform resulting in lower system costs, easier maintenance and simplified system installation. In addition, the RSLogix 5000 software used to program the Kinetix Integrated Motion solution allows programmers to easily configure and add drives and motion axes u s i n g w i z a r d - based configuration dialogs. Simple or complex motion profiles can be created with t h e advanced graphical motion profile editor by inserting any of the comprehensive built-in motion instructions i n t o l a d d e r, structured text or sequential function chart application programs. RSLogix 5000 even provides graphical on-line trending for advanced drive diagnostics. Kinetix Integrated Motion is a combination of architecture, A-B world class motion products, and motion application expertise. Ultra3000 drive configuration is made easy using RSLogix 5000 s motion configuration wizards. Even the configuration of a CAM profile can be easily accomplished. The Ultra3000 digital servo drive is optimized to seamlessly interface with Logix via a variety of ControlLogix and SoftLogix motion modules, providing multiple axes of coordinated motion. Features of the Kinetix Integrated Motion solution using the Ultra3000: Single software package for sequential and motion control Seamlessly interfaces with ControlLogix and PC-based SoftLogix motion modules Provides many axes of coordinated motion control Electrical noise immunity Simplified wiring Programming and commissioning performed from one software package: R S L o g i x Advanced drive diagnostic capabilities Graphical on-line trending Simplifies field replacement of drives ControlLogix System Ultra3000 with SERCOS SERCOS Fiber Optic Ring SERCOS (SErial Real-time COmmunications System) is an open controller-to-digital drive interface specifically designed for high-speed, real time, serial communications using noise-immune, fiber optic cables. 3

5 Architecture Flexibility: Simple Integration In many applications, motion control is the most important component to reducing cycle times. For higher performance and lower overall automation system costs, the Ultra3000 provides simple integration into a variety of machine control architectures. It accepts SERCOS and DeviceNet connectivity along with analog 0-10V, step/direction and master following command sources across the entire Ultra3000 family. Traditional Command Interfaces The Ultra3000 interfaces with traditional PC-based and stand-alone motion control systems that generate analog torque and velocity commands. Digital velocity and current loops in the Ultra3000 provide excellent, stable p e rformance and the Ultraware software makes them easy to set up. If your application requires accurate velocity control, the eight preset velocities available on the Ultra3000 allow several speeds to be selected using the drive s digital inputs. In addition, the U l t r a s flexible master/follower mode allows eight different master/follower ratios to be selected using the drive s digital inputs. Ultra3000 with DeviceNet The Ultra3000 with DeviceNet seamlessly interfaces with the DeviceNet architecture. Drive commands can be received via a DeviceNet interface, eliminating control to drive wiring. These features mean less start up time and decreased installation costs. In addition, the Ultra3000 with indexing capability provides a cost-effective package that eliminates the need for a PLC motion card in applications where point-to-point positioning is required. DeviceNet 75 Amp Drive with DeviceNet Ultra3000 Operating Modes: 0-10 analog input for torque, velocity or position control Step/directional input (also step up/step down) for electronic gearing with an indexer Master follows capability via the auxiliary encoder input for electronic gearing Eight preset speeds, torques or gearing ratios selectable via digital inputs and serially Dual-loop feedback with auxiliary encoder input for position feedback Ultra3000 4

6 Indexing: Stand-alone Performance Made Easy Ultra3000 indexing: Cost-Reduce and Simplify Your Solution Indexing functionality allows the drive to execute up to 64 different trapezoidal position moves initiated by the use of digital I/O, MMI, or an unlimited number of indexes through the use of the h o s t command language. The benefit of indexing is the ability to obtain the position-control performance and flexibility in applications where electronic motion control systems were not cost-effective in the past. The indexing drives support four different types of index moves: Incremental distance move relative to current position Absolute position move in reference to home position Jog move executed when input level is high Registration distance move relative to registration sensor input The Ultra3000i indexing drive allows you to define the following parameters for each index profile: Index type Velocity Dwell Time Distance (positioning) Acceleration Next Index Registration Distance Deceleration Batch Count Action when Complete Ultra3000i Indexing with Ultraware Features of the Ultra3000 with indexing: 64 configurable index profiles for absolute, incremental, registration, and jog type positioning Ability to blend indexes with a non-zero velocity Built-in homing routines Eight preset positions for control of an i n d e x s progress via a digital input Direct serial communication interface between Ultra3000i servo drive and P a n e l View Plus reduces hardware, saving time and reducing costs Home Routines The Ultra3000i offers a user-defined home routine, which allows you to home the axis without the aid of other devices. Using Ultraware, you can select one of the following different home routines to match your motion application: Blended Moves Blended moves extend the positioning capability of the Ultra3000i by allowing it to finish an index move at a nonzero velocity and immediately begin the next specified move. As the picture illustrates, one index can immediately lead to a second without stopping. Blended indexes are easily set up in Ultraware. Home-to-sensor-to-marker Home-to-sensor Home-to-current-value-to-marker Home-to-marker Home-to-current value Ultra3000i Homing with Ultraware Index 1 Index 2 Position 5

7 U3k_broch10_04_04rev.qxd 10/12/04 9:27 AM Page 7 A Broad Range of Servo Motors to Fit Any Application MP-Series Low-Inertia Brushless Servo Motors MP-Series low inertia, high output, brushless servo motors feature a design that reduces motor size while delivering significantly higher torque. Available in seven frame sizes, these motors provide continuous torque from 1.58 to 163 Nm ( lb-in.), with a peak torque range of 3.3 to 271 Nm ( lb-in.). Motors feature speeds up to 5000 rpm, and an absolute feedback option eliminates the need for a homing routine. MP-Series Integrated Gear Motors The MP-Series Integrated Gear Motor line offers a compact motor and gearbox combination for high torque applications with limited space. Available in three frame sizes, these motors provide continuous torque from 15 to 700 Nm ( lb-in.) and peak torque from 32 to 1300 Nm (283-11,500 lb-in.). MP-Series Food Grade Motors The Allen-Bradley MP-Series Food Grade Motors combine high-efficiency, high-torque capability with features specifically designed to meet the unique needs of food and beverage packaging and handling applications. Available in four frame sizes, they provide continuous stall torque from 1.6 to 19.4 Nm ( in-lb) and peak torque from 3.6 to 48.6 Nm ( in-lb). 1326AB Brushless Servo Motors 1326AB medium inertia brushless servo motors with high resolution feedback are specially engineered for high continuous output and smooth performance. Available in three frame sizes and a wide torque range ( Nm), the encoder based version of this series of servo motors is intended to be used with the Allen-Bradley Ultra Family drives and is available with multi-turn absolute option. F-Series Medium-Inertia Brushless Servo Motors F-Series motors, mechanically interchangeable with the MP-Series low inertia motors, use a ferrite magnet that provides nearly five times greater inertia than the MP-Series for matching larger-load inertias. Available in two frame sizes, the F-Series motors range in continuous torque capability from 3.5 to 24 Nm (31 to 210 lb-in.) and speeds to 4000 rpm. The F-Series motors use an optical 2000-line incremental encoder (5000-line optional) for superior low-speed performance with the Ultra Family. Y-Series Small, Low-Inertia Brushless Servo Motors Y-Series motors, available in either 115V or 230V windings, use a high-energy neodymium magnet that provides low inertias for fast acceleration. Available in three popular metric frame sizes, the Y-Series motors range in continuous torque capability from.17 to 2.5 Nm (1.5 to 22 lb-in.) and speeds up to 5000 rpm. Their outstanding torque-to-size ratios make the Y-Series a powerful combination with the Ultra Family drives. Cables and Accessories When it comes to motion control systems, efficient commissioning and superior uptime are a direct result of simple, easy-to-understand interconnects and integrity in every component. You ll find that using the standardized cables and accessories designed specifically for the Ultra3000 means fewer problems, more efficient operation, less downtime, and quicker troubleshooting. We ve taken great care to ensure that Ultra3000 accessories provide unquestionably sound connections, long life, and superior performance. 6

8 Ultra3000 Digital Servo Drive Specifications ELECTRICAL CHARACTERISTICS 2098-DSD DSD DSD-HV DSD-HV DSD DSD DSD-HV DSD-HV DSD DSD DSD-HV100 Peak Output Current (Amps) 7.5/15/30 30/75/150 14/22/46 68/94 Continuous Output Current (Amps) 2.5/5/10 15/35/65 7/11/23 34/47 Continuous Output Power (kw) 0.5/1/2 3/7.5/15 3/5/10 15/22 INPUT Continuous Input Current (Amps RMS) 5/9/18 28/30/46 4/7/14 20/28 Input Voltage Volt AC Single-Phase (Three-Phase for -075 and -150) Volt AC Three-Phase Auxiliary Power Optional 5 Volt DC external logic power Input Frequency Volt DC required for Digital I/O Hz OPERATING MODES AND COMMAND SOURCES Ultra3000 Analog Velocity/Current Mode +/- 10 Volt input Preset Velocity, Current, and Follower Ratios 8 presets, binary selection by digital inputs or serial commands, electronic gearing Step and Direction, Step Up/Step Down 2.5 MHz maximum frequency, Differential or single-ended input Master Encoder Following 2.5 MHz maximum line frequency, Differential or single-ended input Digital Serial Commands Via serial port and 7-bit ASCII protocol Modes Current, Velocity, Postion control Indexing 64 configurable indexes, selectable by digital inputs or serial commands Blended moves at a nonzero velocity, Jogging, Stop Index via digital input or serial command Positioning Types Absolute, Incremental, Registration, Jog Home Routines Home-to-sensor, home-to-marker, home-to-sensor/marker, or home-to-current-value SERCOS SERCOS interface Languages Ladder, Structured Text and Sequential Function Chart INPUTS/OUTPUTS General-Purpose Digital Inputs General-Purpose Digital Outputs General-Purpose Relay Output Registration Input Capture Response Analog Command Input General-Purpose Analog Output COMMUNICATIONS Serial Networking MOTOR FEEDBACK Input Modes Maximum Input Frequency Commutation Startup AUXILIARY FEEDBACK Operation Input Modes Input Type Maximum Input Frequency 8 Optically Isolated Volt, Active High Inputs - Assignable to one or more selections 4 Optically Isolated volt Outputs, 50 Milliamperes Maximum 1 Normally Open Relay, 30 volts DC Maximum Voltage, 1 Ampere Maximum Current <100 µseconds 1 14-Bit Analog-to-Digital Converter (+/- 10v, Differential) 1 8-Bit Digital-to-Analog Converter (+/- 10v, +/- 2mA, single-ended) 1 port with RS-232/RS-422/RS-485 at ,600 baud DeviceNet Incremental with Index, Sine/cosine High Resolution Absolute (Single and Multi-turn) 2.5 MHz (Encoder Lines), Over 1 million counts/rev (High Resolution) Hall Sensor Auxiliary Position Loop Feedback Input A quad B Line Receiver 2.5 MHz (Encoder Lines) HV indicates the V AC version of the drive All drives available in indexing, non-indexing, SERCOS, DeviceNet or indexing DeviceNet versions A Kinetix Integrated Motion Solution: Smart Belt with Ultra3000 Digital Servo Drive and ControlLogix SERCOS interface 7